Device to collect moisture from open decks

ABSTRACT

A deck pan arrangement for an open deck which includes a plurality of joists is provided. In a preferred embodiment, the deck pan arrangement includes a plurality of planks for connection with the joists. The planks have an upper surface and descending legs. A separate or integral deck pan is fitted between gaps between the planks.

BACKGROUND OF THE INVENTION

This application claims the benefit of non-provisional patentapplication No. 10/214,432, filed Aug. 7, 2002 and is a continuation inpart of the same.

The field of the invention pertains to open decks usually made of woodthat are commonly attached to modern homes. The decks are used foroutdoor relaxation and entertainment and may be constructed from a fewinches to many feet above ground. The decks are planked with gaps of onequarter inches or less to allow for expansion and contraction of theplanks. As a result, water and small debris passes between and fallsonto whatever is below the deck.

Absent the water draining from the deck, the space beneath the deck canbe used as dry storage for a variety of purposes, depending on theheight above the ground. Storage of various outdoor furniture items,portable barbecues used on the deck and yard maintenance items could bestored out of the rain and in the off season, for example. Where thedeck is a significant distance from the ground, the deck could serve asa carport or open boat house. Thus, an economical, unobtrusive andeffective device to collect water passing between the planks of a deckwould be a desirable addition to a new or existing deck.

SUMMARY OF THE INVENTION

The new device comprises a plurality of deck pans supported by the deckjoists and shaped to direct the moisture to a collecting trough which,in turn, directs the water to a vertical drain pipe or downspout. Fornew construction, the deck pans are joined to fit over parallel adjacentjoists and are held in place by the planking applied thereover. Forexisting decks, the deck pans are attached to the sides or undersides ofthe adjacent joists. The deck pans and troughs are formed with specificpitches to minimize collection of standing water in the deck pans andtroughs. The deck pans may be ganged to extend their length.

The new device includes various optional features to reduce or eliminatethe exposure of the joists, headers and other structural members tomoisture. These features have become particularly important in view ofthe severe future reductions and bans on the use of heavy metalcompounds to treat lumber to prevent decay.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a side cutaway section of the deck pan constructiontaken longitudinally between two joists;

FIG. 2 is a top view of a deck pan;

FIG. 3 is a side view of a deck pan;

FIG. 4 is an exploded end view taken at the juncture of a deck pan witha collection trough;

FIG. 5 illustrates a side cutaway section of an alternative form of thedeck pan construction taken longitudinally between two joists;

FIG. 6 is a front cutaway section taken perpendicular to FIG. 5 at thelocation of vertical drains to a collection trough;

FIG. 7 is a partial top view of the installed deck pans prior toinstallation of the decking;

FIG. 8 is a partial section above a collection trough illustrating aprotective deck installation;

FIGS. 9A, 9B and 9C illustrate installation of the deck pans at theheaders;

FIGS. 10A, 10B and 10C illustrate an attachment bracket;

FIGS. 11A and 11B illustrate detailed attachments with the bracket ofFIG. 10;

FIGS. 12A and 12B are side and top views, respectively, of header coversto lap over the brackets of FIG. 10;

FIG. 13 illustrates installation of the deck pan at an outside header;

FIGS. 14A and 14B illustrate vertical views of alternative attachmentsof deck pans to the varmint shields;

FIGS. 15A, 15B, 15C and 15D illustrate in detail a closed end deck pan;

FIGS. 16A, 16B and 16C illustrate alternative deck pans and fasteningmeans for molded composite deck planks;

FIG. 17 illustrates composite deck planks having integral deck pans; and

FIGS. 18A and 18B illustrate metal deck units combined with supportingdeck pans.

FIGS. 19,20 and 21 illustrates composite deck planks having integraldeck pans alternative to those shown in shown in FIGS. 17 and 18A

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Illustrated in FIG. 1 is a portion of a deck comprising verticalsupports 10, horizontal beams 12 supporting joists 14 and headers 16.The joists 14 and headers 16 support the parallel planks 18 of the deck20. Typically, the deck 20 is located adjacent a building 22, and theplanks 18 are spaced apart 24 to accommodate seasonal thermal expansionand swelling.

Under the deck 20 between the joists 14 are a pair of formed plastic ormetal pans 26 and 28 that are fastened into position before the deck 20is assembled to the joists 14. Each pan 26 is shaped as shown in FIGS.2, 3 and 4 wherein an overlapping peripheral flange 30 extends abouteach sloping side 32 and the shallow end 34 of the pan. The flange 30overlaps on the joists 14.

The deep end 36 of the pan 26 upon installation extends over a trough 38perpendicular to the joists 14 and therebelow. The assembly may includea varmint shield 40 as shown to prevent birds and rodents from enteringthe trough 38 or the pans 26. With this construction, the pans 26 and 28gather all of the water that seeps through the gaps 24 between theplanks 18 of the deck 20. The water flows to the trough 38 and fromthere to a downspout (not shown).

Illustrated in FIGS. 5 and 6 is an alternative form of the pan 26wherein the trough 38 is adjacent the header 16. The pan 26 is modifiedto include a drain pipe 42 leading to the trough 38. Adjacent one end 44of the trough 38 is a downspout 46. The drainpipe 42 end of the pan 26is closed off at 48 and flanged 30 over the header 16.

As an alternative a conventional eavestrough 50 may be mounted on theheader 16 and apertures formed in the header 16 to allow water to passthrough from the pan 26 into the eavestrough 50 as indicated by a dashedline 52. Where pans 26 and the other features are to be added to anexisting deck 20 without removal of the planking 18, the flanges 30 maybe bent downwardly as indicated by dashed lines at 54. Or, the pans 26may be manufactured with downwardly extending flanges 30 specificallyfor retrofitting existing decks.

As specific examples the deck pans 26 can be manufactured for 16 or 24inches on center joists 14 and in lengths of 4 to 10 feet to accommodatedecks of various widths from the building 22. The deck pans 26 areV-shaped and formed with at least one-quarter inches per foot slopeleading to the trough 38 to prevent pooling and stagnant water in thepans. The trough 38 is either formed or mounted to provide at leastone-quarter inches per foot slope also.

FIG. 7 illustrates the deck with deck pans 28 installed. The flanges 30overlap, however, in this embodiment the fasteners are hidden, and deckplanking brackets 56 are also attached by the hidden fasteners. Notches58 are also formed in the flanges 30 to drain any water that collectsabove the headers 16. FIGS. 8 through 11 detail the construction shownin FIG. 7 as follows.

In FIGS. 8 and 11, parallel joists 14 support deck planking 18 and deckpans 28 as above, however, the lowermost flange 30 and bracket 56 thereabove are fastened by a hidden nail or screw 60. The screw 60 is coveredby the flange 30 of the next adjacent deck pan 28. The uppermost flange30 of the next adjacent deck pan 28 includes a lip 62 extending into theV-notch 64 of the bracket 56. A second screw 66 attaches the deckplanking 18 to the bracket 56 at a location offset from the joist 14.Where the joist 14 is a rim joist as shown in FIG. 11A, a rim joistcover 68 protects the screw 60. The bracket 56 provides the additionaladvantage of spacing screw 66 further from the deck plank end 70 toreduce the likelihood of splitting the plank 18.

As shown in FIG. 9, to protect the header 16 the flange 30 is formedwith drainage notches 58. The notches 58 allow any water that collectsabove the header 16 to drain into the deck pan 28. The header is notchedat 72, as shown in FIG. 9A, to accommodate the notches 58. FIG. 9Cillustrates a section through the flange 30 at the notches 58.

In FIG. 10, the bracket 56 is shown separately and comprises a V-shapehaving a flange 74 with fastener holes 76 to one side and a blank flange78 to the other side. At the bottom of the V are holes 80 to permitwater to drain from the V-shape into the deck pan there below. Theflange 78 is preferably slightly higher than the flange 74 toaccommodate the upper flange 30 as shown in FIG. 11. The holes 76 areplaced to match the oblong holes 82 shown in FIG. 9B.

FIG. 12 illustrates the rim joist cover 68 of FIG. 11A. The rim joistcover 68 may be notched 84 periodically for drainage but otherwise isflat 86 with lips 88 and 62 to either side for shedding moisture andprotecting the underlying rim joist 14.

As shown in FIG. 13, where there are railing posts 90 and trim boards 92and 94, the rim joist cover 96 is modified to protect not only the rimjoist 14 but also the trim board 94 that is bolted 98 to the rim joistalong with the post. The construction is otherwise as shown above.

In FIG. 14A, two deck pans 26 and 28 come together with a gap 100 therebetween. Water can fall through the gap 100 to the drainage trough 38there below. Where varmint shields 40 are installed between the deckpans 26 and 28 and the drainage trough 38, wind cannot blow and spraythe falling water. Where no varmint shields are installed, screens 102descending from the gap 100 can help control water flow to the drainagetrough 38.

FIG. 14B offers a simpler solution where water spray is not a problem.The bottom of one deck pan 26 extends 104 over the bottom of deck pan28. The bottom of deck pan 26 includes raised portions 106 to permitwater from both pans to easily pass underneath deck pan 26 and fall fromthe end 36 of deck pan 28 down into the drainage trough.

FIG. 15 further details the construction of FIGS. 5 and 6. The FIG. 15construction is particularly suited to installations where the deck isenclosed on three sides by walls thus requiring the deck pan flange 30to extend on all four sides of the deck pan 26. The drain hole 108 isspaced from the entire flange 30. The peripheral construction comprisingoverlapping flanges 30 and brackets 56 is as disclosed above. The drainholes 108 may lead to individual drain pipes or a drainage troughperpendicular to the joists.

FIG. 16 illustrates deck pans 110 adapted for use with composite decksurfaces 112. As shown, the deck pans 110 fit under the outside legs 114of the deck surfaces 112 to collect water falling through the gaps 116between the legs. A variety of devices can be used to retain the decksurfaces 112 and deck pans 110 to the joists 118. In FIG. 16A, barbedfastening clips 120 grip the center legs 122 of the deck surfaces 112.The clips 120 are screwed 124 to the joists 118. In FIG. 16B, wire clips126 are screwed 128 to the joists 118 and fit in holes 130 in the centerlegs 122. FIG. 16C details placement of the screw 128 against the bottomof the ring 132 to force 134 the clip 126 downward tightening the decksurface 112 to the joist 118 as the ring 132 engages the bevel under thescrew head.

FIG. 17 shows a modified composite deck surface 136 wherein the deck pan138 is integral with the deck surface. As above, water flows through thegap 140 between the deck surfaces, and the deck surfaces are clipped 142by the center legs 144 to the joist 118 below.

In FIG. 18A, metal deck units comprise deck surfaces 146 atop integraldeck pans 148. The deck pans 148 are fastened to the joists by twistedstraps 150. The deck surfaces 146 overlap the deck pans 148 in the samemanner as shown for the composite surfaces in FIG. 17. The straps 150can be pre-riveted 152 to the metal deck units and pivoted and twistedinto position as the deck units are installed. FIG. 18B illustrates adeck unit with the strap 150 down but not twisted. The deck surface 146may have plastic snap on surfaces as shown.

Referring to FIG. 19 a composite deck plank 220 is provided havingthickened support legs 222 and an integral trough or channel section224. The plank 220 may have a surface treatment or a composite mixturethat contains a herbicide, fungicide and or fire retardant if desired.The plank 220 can be connected to the underlying joists with the methodsshown in FIGS. 16A, 16B, or by the use of flange member 226 FIG. 20(with the aid of fasteners 228 and 230), or by the use of a L-bracket233 (with the aid of fasteners 232 and 234). Typically flange 226 andbracket 231 will be fabricated from sheet metal.

In FIG. 21 a metallic (typically steel) deck pan 240 is provided. To addrigidity and strength the deck pan/surface 240 has integral leg members250. An extra wide wood, cellulosic, polymeric or ceramic or compositedeck surface 252 is added on to which will typically be a cooler surfaceto walk on than the metal surface. Again the deck surface may have thechemical treatments mentioned for the plank 220. The deck surface 252 iswider than the deck surface 146 and therefore installation time isreduced. The connection between the deck surface 252 and the deck pan issimilar or identical to the connective arrangement shown in FIG. 18. Ifso desired two narrow deck surfaces 253 can be utilized instead of thelarger deck surface 252 so that an alternating color or texture patternmay be utilized.

1. A deck pan arrangement for an open deck which includes a plurality of joists, said deck pan arrangement comprising: a plurality of planks for connection with said joists, said planks having an upper surface and descending legs; and deck pans fitted under gaps between said planks.
 2. A deck pan arrangement as described in claim 1 wherein said legs of said planks are retained to said joist by a barb-fastening clips.
 3. A deck pan arrangement as described in claim 1 having a clip fitted within said plank and wherein said clip is screwed in to a side surface of said joist and wherein tightening of said screw causes said clip to urge said plank toward said joist.
 4. A deck pan arrangement as described in claim 1 wherein said legs of said planks hold said deck pan to said joist.
 5. A deck pan arrangement for an open deck which includes a plurality of joists, said deck pan arrangement in combination comprising: a plurality of deck planks having an upper surface with legs extending towards said joists, said planks being connected to said joists; and an integral deck pan formed by said planks underlying an adjacent plank.
 6. A deck pan arrangement as described in claim 5 having a removable top surface.
 7. A deck pan arrangement as described in claim 6 wherein said top surface is fabricated from an organic material and a major portion of a remainder of said plank is made from a metallic material.
 8. A deck pan arrangement as described in claim 5 wherein said legs are thickened.
 9. A deck pan arrangement as described in claim 5 wherein said deck plank surface has a fungicide, herbicide, or fire retardant.
 10. A deck pan arrangement as described in claim 6 wherein said top surface has a snap-on fit with a remainder of said deck plank.
 11. A deck pan arrangement as described in claim 5 wherein said deck plank has an M shape with a lateral deck pan.
 12. A deck pan arrangement as described in claim 11 wherein said deck pan arrangement has two top surfaces. 